Noncaking alkyl aryl sulfonate detergent compositions



March 17, 1953 A. H. LEWIS 2,631,980

NONCAKING ALKYL ARYL SULFONATE DETERGENT COMPOSITIONS Filed July 22, 1949 4 shee's-sheet 1 PRDPYLENE cATALY'Tlc PoLYMERlzATloN oLEoFlNEs BDlLlNG BELow 3ooF FRACTIONATION `y BOTTOMS BOILING ABOVE 6ooF DETERGENT PRODUCT ah/@QL ATTORNEY FIGI A. H. LEWIS March 1 7, 1953 NONCAKING ALKYL ARYL SLFONATE DETERGENT COIVIPOSI'IIIIONS*` 4 Sheets-Sheet 2 Filed July 22, 1949 ATTOR NEY A. H. LEWIS March 17, 1953 NONCAKING ALKYL ARYL SULFONATE! DETERGENT COMPOSITlONS 4 Sheets-Sheet 5 "Filed July 22, 1949 INVENTOR ATTORNEY March 17,' 1953 A. H. LEWIS NONGAKING ALKYL ARYL SULFONATE DETERGENT COMPOSITIONS Filed July 22, i949 4 Sheets-Sheet 4 "loHoD-ly NOLLVI'IOS DIJSDVD INVENTOR Allen H. Lewis ATTORNEY Patented Mar. 17, 1953 NONCAKING ALKYL ARYL SULFONATE DETERGENT COMPO'SITIONS Allen H. Lewis, Berkeley, Calif., -assignor ,to Galifornia Research Corporation, San Francisco, Calif., fa corporation of Delaware Application July 22, 1949,1Seral N o.-'I0`6,143

6 Claims. l

vThis invention relates to a novel mixture of new phenyl-substituted alkanes and sulfonated derivatives thereof. More particularly the invention is concerned with the production of such compounds 4in which 'the alkane portion of the molecule is of relatively high molecular Weight and preferably contains .from about 12 to about 1'5 `carbon atoms.

In vthe production of sulfonate detergents and particularly their relatively high molecular weight phenyl Aalka'ne components by alkylation or condensation reactions, a paramount problem has been the provision of asuitable alkane. Olens suchV as butene polymers have .been proposed as an alkane source, but .introduce outstanding diiculties which arise from instability of the 'branched-aliphatic chains characteristic of such polymers.

Straight-chain olens are of limited availability and prohibitive in cost. The instability of branched aliphatic polymer chains is reflected, for example, in alkylating and condensation reaction's with benzene or toluene andre- 'sults in degradation of the polymer chain during condensation. 'This degradation leads to the vproduction of a 'mixture of phenyl alkanes containing compounds both lower 'and higher .in aliphatic'molecular weight'than'the .olefin originally selected 'and desired. The instability and degradation of the olen polymers inthe presence of condensation catalysts under alkylating conditions also leads to'the'production of substantially inseparable `polyalkylated aromatics of the same molecular weight and 'boiling range as the desired phenyl alkanes. This is a decided disadvantagesince, upon conversion of such degraded mixtures to the sulfonated phenyl derivatives, relatively low yields have resulted. The sulfonated derivatives tend to be relatively poor in detergent quality and require costly purification treatment 'to eliminate or reduce odor, unsuifonatable residua, color bodies, and other impurities introduced vby degradation caused by the original instability o'f the olefin polymer. I-Ieretofore such deficiencies :have seemed to be inherent in the branched-chain structure of olefin polymers, and the mixture of phenyl alkanes derived from such polymers vhave contained relatively large quantities of polyalkyl'ated aromatics and unsulfonatable residua. .At best .these impurities have `not been entirely y'separable vand 1 `have vimparted undesirable odor or color to the sulfonated products.

An object of this invention is `to produce an improved mixture -of sulfonated phenyl substituted 'branched-chain alkanes of relatively high molecular weight and excellent detergency.

A 'further object is -theproduction of a kmixture Aof phenyl all/lanes having a low unsulfonatable residue and a .branched-chain structure.

Additionally, an object of the invention is to furnish phenyl alkanes convertible to sulfonatedphenyl alkane detergents of good color and having 'an exceptionally low content of deleterious vdegradation products for impurities.

Another object lof the invention is to provide a novel 'mixture lof phenyl sulfonate substituted alkanes having valuable 'detergent properties.

A further object is to produce an improved detergent comprising a mixture of phenyl alkane sulfonates of improved color and odor.

Other objects and advantages of the invention will become apparent from the following description and the drawings in which:

Figure 1 is a flow sheet illustrating in block diagram the majorfeatures and process steps for the production of a mixture of phenyl alkanes and conversion thereof to a phenyl-sulfonate substituted alkane mixture in accordance with the invention.

Figures J2, 3 and 4 when taken together and laid nside by side from left to rightin their respective order, show in diagrammatic form a process with the principal units of apparatus for conversion of propylene and benzene to Yan effective detergent.

It has been discovered that the foregoing objects can be accomplished by deriving a phenyl alkane from an olefin polymer, preferably a propylene polymer, in which the ratio of co1'- rected optical density of the polymer at about 10.35 mu to corrected optical density at about y11.23 mu is greater than unity.

Aliphatic mono-olefin polymers satisfying the foregoing requirements can be obtained by polymerizing propylene, preferably in the presence of an excess of propylene dimer and of an acid polymerization catalyst. Propylene polymers, When characterized by a ratio of corrected optical densities as previously set forth, possess a branched-chain structure which has marked resistance to degradation or fragmentation in the presence of highly active alkylation or condensation catalysts, such as anhydrous hydrofluoric acid. The preferred propylene polymerization conditions utilize a phosphoric acid polymerization catalyst and yield a polymer mixture having a molecular weight predominantly in the C9 to C18 range, which mixture upon proper fractionation gives a high yield of mono-olefins of the desired branched-chain structure boiling within the range of 360 to 520 F.

It should be noted at this point that it is virtually impossible to dei-lne in terms of precise chemical structure the new mixture of compounds obtained according to this invention. However, the foregoing ratio of optical densities is definitive of chemical type structures of components of the mixture and is indicative of the relative proportions of different types of components con-V tained therein, as will be apparent from the folu lowing discussion.

Infrared absorption bands are caused by natural vibrations of the molecules of a chemical compound. Each atom in a molecule is free to vibrate about the other atoms to which it is bonded and does it with a natural and characteristic frequency. As the molecule is irradiated with light of this frequency, energy is absorbed by the molecule causing it to vibrate and thereby diminishing the intensity of the light which is transmitted. Likewise, each pair or characteristic group of atoms in a molecule has its own natural modes or frequency of vibration. The difference between the absorption frequencies different chemical groups are often great enough to permit positive identification of the principal functional groups in a molecule. Thus, by irradiating a chemical compound or a mixture of compounds with infrared light to obtain the complete infrared absorption spectrum of the composition, one may obtain the sum of the contributions from all of the characteristic chemical or functional groups in the material and thereby determine its principal type components or features of chemical structure. Many of the correlations which have been made between molecular structures and frequencies of absorption bands are given in Table I.

4 It has been found that infrared absorption and optical density in the 10.35 and 11.35 bands characterize olefin polymers having high resistance vto fragmentation and degradation by anhydrous hydrofluoric acid.

The following data are illustrative:

These data show that the ratio of corrected optical density (De) at 10.35 mu to corrected optical density to 11.25 mu is greater than 1 for olen chains of polypropylene structure, whereas non-equivalent olefins, exemplified by polymers of the butenes are characterized by a value of less than 1 for the same rat-io. Thisratio of corrected optical densities at 10.35 mu and 11.25 mu is hereinafter termed R factor.

Likewise, the foregoing data illustrate the fact that the desired olens of polypropylene structure possess a molecular (Ema) extinction coeicient greater than 10 and preferably greater than about 12 at 10.35 mu, whereas non-equivalent olens have a molecular extinction coefficient less than 10 in this band.

The following test procedures are utilized for determining the above values.

TEST PROCEDURE Foa DETEBMINING R FACTOR Using an infrared spectrometer equipped with liquid cells of approximately 0.1 mm. in thickness, accurate optical density measurements of the olefin sample are made every .02 to .04 mu in the 10.35 mu absorption band (for example from 10.2 mu to 10.5 mu) and in the 11.25 mu absorption band (for example from 11.1 mu to 11.4 mu). An infrared spectrum is drawn plotting optical density as the ordinant v. wave length as the abscissae. The molecular weight and specific gravity of the olefin sample are measured by the usual methods. The optical density value corresponding to the peak of the absorbed band near 10.35 mu and near 11.25 mu are read from the spectrum, and each is corrected to a molecular weight basis of and a specific gravity of 1 as follows:

D D (measured) (Mol. wt.) X 1 ce (Specic Gravity) X 100 R. factor is then determined as follows:

Da at 10.35 mu R D. at11.25 mu A value greater than unity for the R factor indicates a satisfactory propylene polymer and a polymer having a relatively high proportion of olens with the structure:

tation in the presence of active alkylation or condensation catalysts and shows that the polymer Polybutene phenyl-sulfonate lmixture contains a relatively high proportion pf olens having the structure:

Alaspreviously:indicated theexact chemical constitution ofthe compositions produced :according tok this invention `.cannot be preciselydefined.

Signicant dierences in chemical structure and composition of the Imixed phenyl-sulfonate substituted alkanes of this invention are shown by the following data o n detergency:

Table V yDetergency 1 (l2 aliphatic carbons) Polypropylene phenyl-sulfonate (C12 alkyl) 46 1Measured by relative whiteness of cleansed fabric.

`4n R C However, the infrared absorption .spectrum clearl "l 5 ly indicates that the olens of polypropylene R' .11 structure are largely of .the type: TEST 'PROCEDURES ron 'DETERMINLNG MOLECULAR .R C=C.. Rf

EXTINCTION CcErFIcIENT ii 1| The optical density o f the olefin .sample .COrrelo Telthe'lhan sponding to the peak of the absorption band R-C=C"H near 10.35 muis obtainedas in the test procedure R' H fordetermin'ing R factor. From this measured It appearsnecessarilyto follow that thegphenyl optical density the measured molecular weight polypmpylene 4alkmms `mi the Sulfonates-there- 0f the Sample en@ the measure@ SDe C1f`1C gravlty, 15 of are complex mixtures characterized by the .the molecular eXtlnClOl eeefelent 1S Calculated branched-chin structure of polypropylene .Landa as follows: tertiaryv Aalkyl l.carbon 'atom at .the benzene :ring E,1 at 10.35: bhw H D(measured at 10.35 mu) X (M01 Wt. 20 f 1000x (speci-ee gravityyx (thickness ofY R?e-R sample in centimeters) Values greater than l0 for Emol at 10.35 mu and preferably greater than 12 indicate a satisfactory polymer having a relatively high concentration of olens .of the structure: v

1i-@aa einen., H H l 1li Non-equivalency of diierent branched-chain .30 olens in the HF alkylation of benzene are illustrated by the following:

Table III Alkylation Loss from HF R Factor ,Emol at 10..'35 mu ABenzene andHF Degradation and y Yield Cra Cut Side Reaction Cm Polypropylene Greaterthan1 Greater than 10... 80% Less than 12%.' Q12 Polybutenes. Less.t1.1an 1.. ....y ,Less than l0 Less than 30%... 50% Approx.

Distinctions and non-equivalency of the resultwhere X Vis hydrogen or a hydrogen .equivalent ing mixtures of phenyl alkanes after fractionaof a metal. tion of the crude alkylate to separate a C12 alkane On the contrary it necessarily appears that olederivative is illustrated by the data in Table IV: fins of the `structure Table IV i5 RwC;C Pheuyl Sulfonate Unsulfo- Eli Color C12 Alkane'Pernatable cent Yield Residue whlchcharacterize'the'polybutene mixturesmust Polypropylene C1B Alkyi- Gooi. 100% Approx None- -yleld either degradatmn products of unknown alte. C Mk l 7 F 25W const1tut1on or by 4known 'laws of substitution P Ybutm@ s 5 me" i 00T" '5% 0' will given phenyl aikanes in which the um car.-

'bon atom at the benzene Aring is `Quaternary"rather Even relatively small percentages VVof .unsulthan tertiary; Y ,fonated residue may impart an undesirable .odor to the sulfcnated product particularly -on aging and such small odor-producing residua .have not been successfully eliminated by any knownfpro- .H cedure in various instances. These objectionable 5 odors are especially to be avoided in the produc- RAE-.gm tion of detergents. Additionally, last traces of R -H color bodies frequently present in unsulfonatable residue are removable only with considerable The new mxture of .phenyl alkelne-S Pfefelelfy are synthesized by condensation of benzene wlth diiculty, 1f at all.

a polypropylene of the deslred structure and molecular weight in the presence of a hydroiiuoric acid catalyst. Although aqueous concentrated hydrofluoric acid is. not precluded, substantially anhydrous hydrogen iiuoride is. the

o preferred catalyst, and the condensation reac- 'tion may be carried out at temperatures of `from about '0 Yif". to vabout 125 F., more desirably at from 50 to 100 'F'. Other catalysts such las BFS, mixtures of BF3 Iand HF, A1Cl3 or H2804 are voperative-butless desirable. -V

The crude alkylate is fractionated to yield novel phenyl alkane compositions and preferably the desired fraction is sulfonated to yield an improved detergent as hereinafter disclosed.

'Olens of the preferred structure may be obtained by polymerization of substantially pure propylene under suitable conditions to form a complex mixture of alkanes having an average molecular weight corresponding to from about 12 to about 15 alkyl carbon atoms together with other higher and lower molecular weight polymers from which the C12 to C15 fraction desirably is separated. Mixtures of propylene with saturated low molecular weight hydrocarbons which do not enter the polymerization reaction may be used as a feed stock; for example, propylene containing propane, ethane and methane. Further, a mixture of such hydrocarbons' containing ethylene is not precluded since the ethylene enters the reaction only to a minor extent. However, the propylene feed preferably should be substantially free of impurities, such as isobutenes, which tend to produce instability in the chain structure or to lower the R. factor below unity and the molecular extinction coelicient below 10. Likewise, the amount of normal butene impurities should be kept at a minimum, for example, less than 1% by volume to maintain the R, factor or molecular extinction coefficient at the optimum value.

A suitable feed stock for polymerization is pure propylene or a mixture such as the following:

Percent by Component Volume (Vapor) Methane and Hydrogen 12. Ethene. 5. Ethane. 29. Propene 21. Propane 30. Isobutane. 0. Butene (n) 0.

TOtal 100.

example, 200 to 600 pounds per square inch.`

The resulting polymer product is a mixture of oleiins from which the relatively stable acyclic branched-chain polypropylenes utilized in the present invention are obtained by close fractional distillation.

Preferably the polypropylenes to be converted to the final alkanes in accordance with this invention should boil within the range of from about 300 F. to 600 F., more desirably within the range of from about 325 F. to 520 F., and

preferably within the range of from 360 F. to

520 F'. At least about 50% of such polypropylene fractions preferably should boil above 380 vF. It has been discovered that a mixture of polypropylenes having an initial boiling point of from 360 F. to about 370 F. and an end point of from 465 F. to about 520 F. with at least 50% boiling above about 390 F., upon conversion to the corresponding phenyl-sulfonate substituted acid. Catalyst temperature alkanes yields a superior detergent. Again, the

polymer mixture may be fractionated to yield a C12 polypropylene cut having a boiling range from about 330 F. to about 420 F., at least about 50 of which boils above 350 F. and a C15 polypropylene fraction having a boiling range of from about 420 F. to about 510 F., at least about 50% of which boils above 450 F. Each of these fractions may likewise be converted to phenyl alkanes and to the sulfonate derivative thereof. The foregoing boiling ranges are determined by an ASTM-D-SG standard distillation.

Unsaturation of the polymer fractions desirably should correspond substantially to that of the mono-olens. Inspections of exemplary C12 and C15 polypropylene fractions are as follows:

EXAMPLE 1 Tetramer Test Data Boiling Range (760 mm.) F.- 340-420 Gravity (A. P. I.) degrees. 51` 6 Index of Refraction nu. 1.4370 Viscosity at F.. centistokes. 1.228 Viscosity at 210 F.. do 0. 644 Bromine Number 92 EXAMPLE 2 Pentamer Test Data Boiling Range (760 mm.) F 420-510 Gravity (A. P. I.) ..degrees 45.3 Index of Reiraction nB.. 1. 4502 Viscosity at 100 F .centstokes. 2. 33 Viscosity at 210 F. d 0. 974

Distillation of the pentamer in a Stedman still gave the following results:

Equivalent Parts by Volume (liquid) ,IYSOT Pressure Vapor Overhead Fp" (mm. Hg) Temp., F.

' at 760 mm.

cient greater than 10.

EXAMPLE 3 verhead (ASTM-D-86) l These are vapor line temperatures.

Olens of the foregoing structures and molecu-r lar! weight distribution are condensed withY an aromatic hydrocarbon of the benzene series in the presence of a hydrouoric acid catalyst, as previously stated, to form the mixture of phenyl alkanes of this invention. (Londensatil'mV of the olefin with benzene is preferred but toluene ci' xylene also is embraced within the broader aspects of the invention. Likewise, the invention also includes in its broader aspects con'- densation of the olens with benzene sulfonic acid, that is tov say, sulfonation of the benzene nucleus can be effected before rather than after the alkylation or condensation stage of the process, although such procedure is presently re*- garded as less desirable.

A hydrofiuoric acid catalyst has been found highly advantageous for effecting the foregoing condensation reactions of polypropylenes with benzene, despite the fact that prior literature and experience indicates that this catalyst acts severely to decompose branched-chain olens intoy shorter chain fragments during the condensation reaction. When the olefin is of the structure and composition herein disclosed, the condensation reaction goes smoothly with minimum formation of undesirable side reaction products characteristie of chain fragmentation or degradation.

Asindicated in Fig. 1 of the drawing, benzene, hydroucric acid catalyst and the selected polypropylene fraction are passed to an alkylation stage where the exothermic condensation or alkylation reaction occurs. The temperature desirably is maintained between from about 50 F.

to about 100 F. by indirect cooling of a closedreaction chamber. Relatively large amounts of hydroluoric acid such as 200 to 800 mol per cent based on the olefin are suitable. Since the olefin is relatively expensive, an excess of the benzene is usually adopted to effect more complete conversion of the polypropylene to phenyl alkane and to minimize a condensation of two or more olefin molecules with the same aromatic nucleus. Uponv completion of the reaction the hydrofluoric acid catalyst is separated from the alkylation mixture,l

as by vaporization, and residual traces thereof may be removed by washing with aqueous alkali.

Following the line of flow in Fig. 1, the alkyla'- tion mixture is distilled first to remove excessI benzene (which is recycled to the alkylation readily separable heavy dialkyl benzenes are' formed containing two C12 polypropylene chains on a single benzene nucleus. These heavy dialkyl benzenes are separated as distillation bottoms and may be withdrawn from the system or ink some instances recycled-to the alkylation stage as indicated by the dotted flow line of Fig. 1.

In those cases where the original olefin isa polypropylene having an R factor greater thanY 1 and a molecular extinction coefcient greater than 12, it has been found that the phenyl alkane overhead fractions boiling within the ranges above indicated are of superior purity. These alkanes are substantially free of objectionable color bodies,y yield little or no unsulfonatable residue,- and contain substantially the same-numv 1U" berof carbon'vatoms in the single alkane chain; of themolecule as were present in thev original? alkene. The relatively high purity and stability of the phenyl alkane products of the reaction makes possible the production of sulfonates and other derivatives without the necessity for de# colorizing treatments with adsorbents or stabilie zation by sulfuric acid treatment which heretofore has complicated the production of such de# rivatives. Also, it has been found that the high purity and stability of the phenyl alkanes of this invention yields sulfonates which are relatively free of undesirable odor not onlyT immediately after their production but after long periods of storage during which time various other sul--v fonates derived from petroleum raw materials' have developed objectionable odors. d

In practicing the invention according to Fig. 1 of the drawing, the phenyl alkane fraction is next sulfonated with any suitable sulfonating agent, such as chloro-sulronic acid or, prelerably,

a filming sulfuric acid. A suitable sulfonating agent 1s Irom b to 25% fuming H2504, in the ratio ci Irom 2 to 5 mois of acid per mol phenyl alkane. About 3 mols of acid per mol of alkane is preferred'. 'lne temperature during initial stages of the sulfonation reaction desirably should be kepty below 115 l. by cooling and adding the acid slowly to the phenyl alkane. To obtain substantially complete reaction temperaturesabove about '11. should be reached; up to about 140 F. is permissible. Thorough agitation should bemaintained, and local overheating avoided to minimize or preventv side reactions during the sulionation. The-spent acid layer may be separatedl aneutralization stage where caustic alkali solution is added to form the sodium salt ol' the sulfonic acid radical now attached to the phenyl group of the alkane by reason of the sulfonation treatment. rlhe neutralized phenyl-sulfonate substituted'alkane ows in the form of an aqueous slurry or paste to a suitable drier where' the finished detergentproduct is obtained.-

rf'he sulfonate product is a complex' mixturefof' substituted alkanes in which the alkane portionv of the molecule corresponds substantiallyI in` molecular weight andstructure to that of the original olenn. uent 0n the'alkarie chain'furnishes a polar group which is correctly' balanced with the non'epolar hydrocarbon structure to yield an excellent' detergent. This sulfonate detergent may be used in substantially pure form but is preferably compounded Withbuilders, additives,.auxiliary detergents or thelike.

One particularly desirable-form of detergent is produced by drum-drying or spray-drying slurry containingsodium sulfate and the neutralized phenyl sulfonated substituted alkanes in proportions to yield a dried product containing from aboutV 50 'to about '70% by Weight,A preferably 55 to 65% by weight of sodium sulfate. inorganic builders'such astetrasodium'pyrophos'- phate,sodium silicate, trisodium phosphatean'd the like-may be incorporated in detergent coni--A ".lhe phenyl sulfonate substit-V 1 1 positions containing the mixed sulfonates herein disclosed. A typical composition is as follows:

EXAMPLE 4 Per cent by weight Sulfonate 3l Sulfate 58 Tetrasodium pyrophosphate l Sodium silicate 1 Additionally, organic additives maybe incorporated in compositions such as the foregoing to enhance the detergency action of the sulfonate on difficult fabrics or stubborn soils. One such suitable additive is a carboxymethyl cellulose sodium salt. This composition may be derived from cellulose by reaction of alkali cellulose with chloracetic acid to form a carboxylic ether which is converted to the sodium salt. A suitable composition is available in commercial form under the name Carboxymethyl Cellulose Sodium Salt (medium viscosity grade). From l to 20% of this additive may be incorporated in a detergent mixture containing about 60% sodium sulfate and 40% sulfonate detergent. It has been found, for example, that 3-5% of this additive in such a detergent mixture increases per cent soil removal from about 40% to about 70% in a standard but severe detergency test at 0.2% concentration of the detergent in hard water. In a similar test at the same concentration, ordinary soap gave only about 15% soil removal.

Reference to Figures 2, 3 and 4 of the drawing will reveal a detailed flow sheet illustrating; an embodiment of the invention, wherein production of a suitable olen from propylene is effected in Fig. 2, the olen and benzene are converted to the desired phenyl alkane in Fig. 3, and the alkane is sulfonated and neutralized to yield the desired detergent in Fig. 4. These three figures when placed side by side from left to right in numerical order form a complete flow sheet of aY preferred process.

Beginning with Fig. 2 there is provided a polymerization cham-ber I0 from which the reaction mixture is passed rst to a stripper II for removing the more volatile components such as xed gases and then to a fractionator I2 for separating C11 and lower olens as overhead. A second fractionator I3 receives the bottoms from fractionator I2 and separates a C12 olen mixture as an overhead fraction. Final fractionator I4 separates the bottoms from fractionator I3 into a C15 olenrmixture as overhead and heavier than C15 hydrocarbons as bottoms. When desired fractionators I3 and I4 may be combined into one fractionation stage with separation ofk a single mixed C12 to C15 olen cut.

A mixture of C12 to C15 olens obtained either by blending the separate C12 and C15 fractions or from the single stage C12 to C15 fractionator is fed to the alkylation stage of Fig. 3 yby way of line i5 and an excess of benzene by valve-controlled inlet line Il. The two hydrocarbon components are mixed in line I8 after which they are dehydrated in fractionating column I9. The dehydrated `hydrocarbon mixture then iiows by Way of line 2I to a sealed contactor 22 provided with a cooling coil 23 for controlling reaction temperature.

Hydroiiuoric acid catalyst is introduced into contactor 22 by Way of feed line 24 and is intimately contacted with the hydrocarbon reactants -by the vigorous action of agitator 26. The hydroiiuoric acid catalyzes the condensation of the polypropylene with the benzene feed to form monophenyl alkanes of the type previously'described. Temperature is controlled and exothermic heat of reaction removed by circulating any suitable refrigerant through cooling coil 23.

As the reaction mixture iiows upwardly through contactor 22, it passes by Way of discharge line 21 to settler 28 where the upper oily phase is withdrawn and conveyed to a fractionator 29 for vaporizing residual volatile catalysts. The residual oily phase is then passed from the bottom of the fractionator 29 through a caustic washing at 3I and is next fractionated to remove excess benzene in distillation column 32. To recover the desired phenyl alkane, distillation bottoms from column 32 are fractionated in column 33 and the phenyl alkane to be sulfonated is recovered as overhead. This phenyl alkane overhead flows from distillation column 33 by way of line 34 to the sulfonation system of Fig. 4.

The phenyl alkane flowing lby way of conduit 36, when desired, may be subjected to a prelimary color extraction stabilizing treatment in a contactor at 36 or this contactor may be bypassed and the phenyl alkane sent directly to sulfonator 3l'. The sulfonated reaction mixture passes by way of overflow line 38 to settler 39 when it is desired to remove excess acid, and the sulfonic acid phase then flows to neutralizer l. Upon addition of caustic soda to the sulfonic acids in neutralizer di, the sodium sulfonates thereby formed pass to a spray dryer 42 with or without further treatment subsequently to be described. promptly packaged as a finished article of commerce.

The foregoing is a general description of the process represented by Figures 2, 3 and 4 of the drawing. In order to facilitate practice of the invention and design of a suitable commercial plant, the following more specific description is submitted.

Referring to Fig. 2, propylene only may be fed or, as here shown, Cei-C11 oleiins selected from the group consisting of straight-chain olens and polypropylene are fed by way of inlet line 59 together with propylene by way of inlet line 5I to mixer 52. The resulting olefin mixture then passes through preheater 53 and feed line 54 to a xed bed solid phosphoric acid catalyst in polymerization chamber I0. Steam also is introduced into the polymerization chamber by way of line 56 in a quantity suiiicient to maintain a partial pressure of water Vapor equal to that of the phosphoric acid catalyst in order to prevent dehydration of the catalyst which is maintained at the desired reaction temperature by heat of reaction. Inter-polymerization of the propylene with the Cs to C11 olens, preferably polypropylene, is elected upon contact with the polymerization catalyst, as they flow downwardly through the catalyst bed, and the resulting polymerized mixture is then conducted by Way of conduit 5l through heat exchanger 53 to stripper column il where low boiling hydrocarbons are removed as overhead through line 53. The gases removed in stripper II comprise mostly propane and propene together with other hydrocarbons containing less than ve carbon atoms. The stripped gas flows through cooler 59 to collecting drum 6I where uncondensed gases may be discharged by way of vent line 62.

In order to regulate the temperature developed by exothermic heat of reaction in the polymerization zone, a controlled portion of the cooled gases and any condensate formed in 'drum vIiI' The dried detergent preferably isy is conveyed by Way of valve'controlle'd linefES and introduced into the polymerization zone as a diluent and cooling gas. To further facilitate control of reaction temperature, valve-controlled conduit E4 is provided for by passing some of the reaction feed directly to the polymerization zone without preheating by heat exchange in preheater 53.

The polymerized mixture, stripped of C5` and lighter gases, flows from the bottom of column II by Way of conduit 65 to the rst fractionator i2 where light olefin polymers in the Cs to C11 range are separated as a vapor phase overhead, which passes by Way of outlet conduit 6l through condenser 68 to condensate drum 69. Fractionation is controlled and improved by returning a portion of the'condensate from drum SQ to fractionator' I2 by way of valve-controlled reflux line 7|.

To increase the yield of C12 to C15 olefins, it is sometimes desirable to return at least a portion of the C5 to C11 oleiins (separated in fractionator I2) by Way of valve-controlled line 'i2 to polymerization zone l5! and thereby cause inter-polymerization of these lovver polymers with the propylene feed to yield additional C12 to C15 olens. Excess Ca to C11y olens may be Withdrawn by means of discharge line i3.

The C12-and higher boiling olefin polymers pass downwardly through fractionating column I2 and ou-t discharge line t4 through pressure reducing Valve 'It to fracticnator I3 Where a C12 olefin fraction boiling, for example, from about 330 F. to about 420 F. at atmospheric pressure is taken overhead through condenser 'il and collected in condensater drum 1B. This fractionation preferably is effected under vacuum which is maintained through vacuum line 'I9 connected to a vacuum pump, steam ejector, or other suitable means for maintaining the required subatmospheric pressure. A portion of the condensate may be returned as reflux to fractionator I3 through valve-controlled reflux line- SI. It is sometimes found desirable to recycle another por' tion of the C12 olefin cut by Way of valve-controlled line 82 through pump 83 to inlet feed mixer 52. The remainder of the'C12 olefin cut is pumped through conduit 84 to vtankage for blending with theA C15 olen cut obtained in the' next fractionation stage'.

The C15 and higher boiling oleiins` flow downwardly through fractionating column i3 and are discharged by Way of line' 86 through pressure reducing valve 8'! into frac-tionator I4 Where a C15 olefin fraction boiling, for example, from about 420 F. to about 500 F. at atmospheric pressure is taken overhead through condenser 88 to condensate drum 89. A. portion of the condensate may be returned to fractionator I4 by Way'of valve-controlled reflux line 9 I, andthe remainder pumped to tankage through line 92 for blending with the C12 fraction. Bottoms from fractionator I4 are discharged to outlet line 93.

It is preferred to operate fractionating column I4 as Well as column I3 under'vacuum in order'to avoid deterioration of the C12 to`C15 olefins by decomposition or further polymerization. Desir-Y ably, fractionatcr lf3 is maintained at higher vacuum than fractionator I3 by means of a vacuum line 94 on condensate drum 89 and connected to any suitable device for maintaining reduced pressure, such as vacuum pump, or steam ejector.

To illustrate suitable operations in the foregoing process, exemplary polymerization conditions are:A

14 ExA-Mrm' Temperature of fresh feed" 350`-4'25''F.'. Temperature of catalyst 375-500ov F. (preferably 41004-4460? FJ.. Pressure 20D-600" lbs/sq.v Propylene feed (as liquid) .O2-0.2 v./v./hr. Catalystv 10U-110% orthophosphoricacid onlzieselguhr.`

A typical feed stockl will' contain. other normally gaseoushydrocarbons in various proportions;-su'cli` asy the following:

EXAMPLE 'GL' Volume Hydrocarbon `Percent- Ethylene Ethnie..." Propylene. Propane Buteue (impurity Butane EXAMPLE 7' Relative Volume Propylene` in Feed Relative` VolumeV Ct to yC11 in Feed' At least about 0.2liquid volume of'Cirt0"C11.1'Jolyn propylene perliquid volumeo'f' propylene'is de sirable. More' than' ten volumes p'ervolum'ei of propylene usually'is not warranted; Intlie forei-Y going runs the average'temperatureA of catalyst was 430" F.; pressure, 200 pounds per' square inchv gauge; and propylene feed rate .032 vi/vJhr: Higher pressures increase theyield of' Ciz" t'o`C1sl olen interpolym'ers as illustrated by the follow# ing data:

f Yield'Percent Spacci-laste'v Basedon* Pressure v./v.[hr. Propylene Feed 200'1bs./sq. in.. 0.` 7'4 8'1 500 lbs/sq. in 0774i 1101 200 lbs/sq. i` 0.1324 eri 500 lbs/sq. in 0132` 121n In some situations it is', therefore, preferred'y tov operate the process at 400 to 600 pounds perJ square inch pressure. In these latter'runs, average catalyst temperature-Was 430` F., and the-ratio of C6 to C11 olens to p'ropylenel was approxi-4 mately 22:1.

Although the'v C12 and the C15' olefinl fractions' may be alkylated separately, preferably a blend of from 60 to 80% of the foregoing C12 olefin fraction with from 40-20% of the C15 fraction is prepared by conveying these respective olefins from tankage by way of valve-controlled outlet lines 96 and 9'! to blending tank 58. The blended olen, boiling within the ranges herein disclosed, then ows together with benzene from valve-controlled benzene feed line Il by way of sulfonation inlet conduit I8 to the alkylation stage of Fig. 3.

The benzene olen mixture from the polymerization system is first dehydrated in fractionating column I9 of Fig. 3. This dehydrating column is operated under total reux. In such an operation, water together with a portion of the hydrocarbons is vaporized overhead, passes through line to condenser |02, and the condensate collected and allowed to stratify in condensate drum |03. The lower water layer is removed by line |04 and the hydrocarbon layer returned to fractionating column I9 by way of reflux line |06. The dehydrated hydrocarbon feed passes from the bottom of column I9 through outlet conduit 2| and cooler |07 to reactor 22. Condensation of the polypropylene with the benzene is effected by catalysis with hydrogen fluoride in reactor 22, and the temperature is controlled by indirect heat exchange with any suitable refrigerant introduced through cooling coil 23 as indicated.

Inasmuch as the hydrouoric acid catalyst which may be introduced through fresh catalyst feed line 24 is not miscible with the hydrocarbon reactants, it is important that intimate contact between the hydrocarbon and hydrofluoric acid phases be effected by vigorous agitation. As here shown, an agitator 26 is provided and is driven by motor I 09 connected thereto by shaft III passing through the bottom of reactor 22. In the construction of this agitator it has been found advantageous not only to provide a hydrofluoric acid resistant bearing and packing for shaft I I l, but also to flush this bearing and packing with fresh benzene admitted by way of valve-controlled line I I2 whereby minimum exposure to the action of hydrofluoric acid is obtained.

After the hydrogen fluoride catalyzed condensation has been effected in reactor 22, the reac- -tion mixture is passed through overflow conduit 27 to settler 28 where a lower hydrofluoric acid phase and an upper hydrocarbon phase are formed. The lower acid phase is withdrawn from the bottom of settler 28 through conduit I I3 and may be recycled to the reactor by way of valve-controlled return line H4 or passed to the hydrouoric acid purification unit, hereafter described, by way of valve-controlled line I I6.

The oil phase in the upper portion of settler 28 contains the excess benzene as well as some hydrouoric acid together with the condensation reaction products. This oil phase is continuously withdrawn through overow III and passes through heater ||8 to benzene stripping column 29 where benzene and hydrofluoric acid are vaporized as overhead and are conducted through line |2| and condenser |22 to condensate drum |23. In order` to improve the separation of benzene a portion of the hydrocarbon distillate collected in condensate drum |23 may be returned to stripper IIS by way of reux line |24. The benzene-hydrouoric acid mixture is withdrawn from condensate drum |23 through line |26 and may be processed as hereinafter described in more detail in one of three ways; namely, by passing the mixture through valve-controlled line |27 to 16 the hydrofluoric acid recovery system, by recycl-l ing directly to reactor 22 through valve-controlled return line |28, or by feeding the benzenehydrofluoric acid mixture through valve-controlled line |29 to a suitable fractionator for separating the two components.

Returning now to the benzene stripper 29, the hydrocarbon reaction mixture stripped of its benzene and most of the hydrouoric acid contained therein flows from the bottom of said stripper through outlet line 3| to a line or bauxite packed treater |32. In order to facilitate continuous operation, two or more of these treating charnbers may be connected in parallel so that one may be replenished while the other is on stream. The lime or bauxite in treater |32 serves to remove a major portion of residual hydrciluoric acid, and may partially decompose or remove any organic fluorides formed in previous stages of the process. The treated hydrocarbon mixture flows from the bottom of treater |32 through line |33 to caustic washer 3| where nal traces of organic fluorides are decomposed or extracted.

Washer 3| contains a lower aqueous caustic layer |34 and an upper water layer |36. The interface between these two layers is indicated by dotted line |37. Desirably aqueous caustic is introduced by pump |38 at washer inlet pipe |39 in the upper zone of the aqueous alkali layer and circulated downwardlyto pump return line |4I. Fresh caustic may be introduced and spent caustic discharged by suitable connections not shown. Water is likewise preferably circulated from upper inlet |1152 to lower outlet |43 in order to provide a countercurrent washing action for removing any entrained caustic. Thus, the hydrocarbon feed introduced by line |33 flows upwardly through rst an aqueous caustic, then through a water layer in washer 3| to outlet conduit |43 and fractionator 32.

Lower-boiling hydrocarbons are separated and the reaction mixture reduced to the desired initial boiling point by vaporization in fractionator 32. The vapor-phase hydrocarbons are taken as overhead through line |46 and condenser |41 to condensate drum |48. Improved fractionation is obtained by returning a portion of the condensate through reflux line |49 to fractionator 32. Condensed hydrocarbons are removed from the condensate drum by way of line I5| and may, when desired, be recycled to reactor 22. The remaining hydrocarbons consisting essentially of monophenyl alkanes and having an initial boiling point within the range, for example, of from 350 to 370 F. are passed from the bottom of fractionator 32 through line |52 to fractionator 33.

Monophenyl alkane product is distilled overhead from fractionator 33 through line |53 and condenser |54 to condensate drum |56. Product having an initial boiling point as above described and an end point, for example, of from 600 to 610 F. is withdrawn by way of line 341 and passed to the sulfonation stage described in connection with Fig. 4. Before proceeding with a description of the sulfonation of this monophenyl alkane product, the hydrofluoric acid recovery system of Fig. 3 will be described.

In the continuous operation of the hydrofluoric acid catalyzed alkylation or condensation system, the hydrofluoric acid catalyst becomes contaminated with water and acid oil until its eificacy as a catalyst is substantially diminished despite the fact that the hydrocarbon feed is carefully dehydrated as described. Thus. the hydroluoric acci-,98o

acid layer separated in settler '28 becomes an aqueous mixture' which must be either discarded or. be suitably treated to recover and purify the same. In a preferred operation, this acid layer or a portion thereof is either intermittently or continuously conducted to a purification unitby way of valve-controlled line H6.

Purification and recovery of the contaminated hydrofluoric acid presents a problem by reason of constant boiling mixtures which' the acid forms with its contaminants. In order to facilitate recovery and purification, fresh benzene is introduced by'way of valve-controlled line v|51 into the aqueous mixture of :line IIB and Vpassed through preheater |58 to fractionating column |59. In this column benzene acts as a stripping agent and carries hydrogen iiuoride as vapor phase overhead through condenser |'6| to condensate drum |62. A portion of the condensate is returned as reflux through line |63 to fractionating column |59. The remaining hydrogen fluoride-benzene condensate is recycled via linev |64 to reactor 22. Bottomsfrom fractionator |59 comprisel a constant boiling mixture of hydrofluoric acid and water together'withV acid oil contaminants and are withdrawn through discharge line |66. Fractionating column |59 thus effects a split between benzene and .hydrofluoric acid on the one hand and a constant; boiling aqueous hydrofluoric acid mixture on the other hand.

Instead of, or in addition to, the fresh benzene fed to fractionator |59 by way of line |51, the benzene hydrofluoric acid mixture from benzene stripper condensate drum |23 may be introduced by way of valve-controlled line |21 into HF recovery line I6 as previously indicated. The relatively large excess of benzene in the mixture from condensate drum |23 serves as a stripping agent and permits economy in the use of fresh benzene.

Alternatively, a portion or all of the benzenehydrofluoric acid mixture from benzene stripper condensate drum |23 may be passed through valve-controlled line |29 to fractionator |61 where fractional distillation effects separation of the benzene and the hydroiiuoric acid, The vapor phase hydrofluoric acid passes overhead through line |163 and condenser |69 to condensate drum |1I. The fractionator may be operated under reflux by returning a portion of the condensate through reflux line |12. Hydrofluoric acid from condensate drum l1| is recycled to reactor 22 by way of line |13 and return Vline |14 vto catalyst inlet |08. Benzene from the bottom of fractionator |61 is recycled to reactor `22 through return line |16.

Exemplary operating datafor the manufacture of monophenyl alkanes in accordance with the foregoing process stage and utilizing anhydrous hydrofluoric acid as a catalyst are:

EXAMPLE 9 Operating Conditions (continuous process) Aromatic feed Benzene Propylene polymer feed z Y Initial bovilnV4 point (ASTM) F 362 End point STM) .F 464 Gravity (A. P. I.) 47.1 Bromine number 103.1

Crudephenyl alkanes (ASTM,distillatlon) Vol. per cent'lighterthan 520 F. 7.5

520 F. to 600 F.: 86.0

Vol. per cent boiling (boilingy above about '600 F.)

Vol. per centbottoms Yields z Vol. crude phenyl alkanes pervol. of polymer..- Vol. benzene consumed per v01. polymer fed Vol. polymer loss to acid oil per vol. polymer e Vol. benzene loss to acid oil per vol. polymer fed Vol. crude phenyl alkanes per vol. benzene used- VofLdfinished phenyl alkanes per vol. polymer In order to guide those skilled in the artin the chemistry of the process and of the composi tions of this inventionrand to more adequately illustrate the preparation of monophenyl alkanes` from C12 and from C15 polypropylene fractions, the following simplified specific examples vare given:

EXAMPLE 10 One hundred milliliters of benzene (81: grams) and 270 grams of anhydrous:hydrofluoriceacidi were placed in a stainless steel, closedreaction` 790.5 grams of crude reaction product was obtained (yield=94%). This crude reaction product was distilled to obtain the monophenyl alkane fraction as follows:

Volume,

Fraction Percent Bottoms 623 FI+ Benzene fraction In separating the monophenyl alkane, the foregoing distillation Was actually carried out at 3 mm. pressure. It will be seen that the yield of vmonophenyl alkane Was 80.8% of theoretical.

The bottoms fraction consisted of phenyl alkanes in which two of the original alkenes condensed these compounds.

with a single aromatic nucleus and about 16% of the original alkene went into the production of Loss to benzene overhead was only'about 3.2%.

Inspections of the monophenyl alkane were:

Gravity (A. P. I.) 30.9 lRefractive rindex nb .1.4884 Specific dispersion 128 Viscosityat F centistokes y v6.60 Viscosity at 210 .F.. do 1.80

This product was essentially a mixture of isomeric monophenyl dodecanes of polypropylene structure believed to contain approximately five methyl groups inthe alkane portion of the molecule.

The propylene-tetramer fraction utilized inthe preparation of the foregoing compound had van A. P. I. gravity of 51.5, a bromine number of 85, and a boiling range of 325 F. to 400 F. Distillaton of this tetramer revealed the following -dS- Y19 tributionvof i'someric dodecenes according to the boiling range: Y

The monophenyl dodecane fraction was 80.5% ofthe total alkylate after removal of excess ben-v zene; 11.5% of the alkylate was lost to overhead Temperature, benzene cut and about 8.0% was lost to distilla- Pereent over ,Jgcgz' 5 tion bottoms. Conversion of olen to alkylate 760 mm.) was essentially 100%.

Inspections on the monophenyl dodecane fracszarr 325 tion were: s 339 1n Gravity (A. P. I.) 31.4 gg 346 10 Specific dispersion 131 45g Refractive index nD2 1.4874 E 55 The propylene tetramer fraction utilized in the g3 preparation of the foregoing compound was 92 15 characterized by the following inspections: gon 400 Boiling range at 760 mm F 340-420 Gravity (A. P. I.) 51.6Y EXAMPLE 11 Refractive index D20 1.4370 825 grams of benzene and 255 grams 0f anhy- Viscosity at 100 F centistokes-- 1.228 nous hydronuoric acid were placed in a Stan- 20 Viscosity at 210 F d0 .644, less steel nasi; equipped with a metal stirrer and Bromine number 92. cooled by an ice water bath as in Example 10,. A E 12 feed stock consisting of 861 grams of propylene XAMPLE tetramer fraction and 1106 grams of benzene was The monophenyl pentadecane fraction was added over a. period of 66 minutes, and the reac- 25 prepared by condensing the propylene pentamer tion allowed to proceed for an additional 60 minutes with stirring at ice bath temperature. The reaction mixture Was diluted with ice and neutralized with aqueous potassium hydroxide soluof Example 2 with benzene in the presence of an. hydrous hydrofluoric acid as a catalyst by aprocedure substantially as described in Examples l0 and 11 above. The data on two such preparations may be summarized as follows:

tion, after which the aqueous layer was drawn Run A Run B Pentadecene Inspections:

Boiling range (760 mm 420-510" F 420-520 F. Gravity, A. P. I..- 44.7. Bromine Number"- 102. Reaction Conditions:

Mol. Ratio (pentadecene: benzene:

HF 1:5.3:2.5 1:524. Temperature Ice Bath Ice Bath. Pressure Atmospheric Atmospheric. Vessel Stainless Steel Stainless Steel. Addition time 5l minutes 60 minutes. Reaction time 3.75 hours. Yield Data:

Reaotants used- Pentadecene 738 gm. Benzene 1640 gm Crude yield after was 2270 gm Crude yield, percent-.- .5. Distillation:

Charge 2270 gm Vol. Wt., Vol. Wt., Percent gms. Percent gms. Cuts- No. 1 (benzene) 75 1, 302 69 1, 567 N o. 3 (monophenyl pentadecanes): 18 320 25' 568 No. 4 (bottoms) 7 120' 6 135 Boiling Ranges at 760 mm.: No. 3 (monophenyl pentadecanes) 515-664" F {S20-680 F. (63% from 580-630) (82% from 580-630) Percent Theoretical Yield 37.2 55.6. Percent of Pentadecene to Bottoms 16.1 14.3. Inspections on Monophenyl Pentadecanes:

Gravity, A. P. I 30.6. Specific dispersion 1 128. Refractive Index m20 1.4886.

The foregoing mixtures of monophenyl alkanes are believed to be novel compositions of matter and possess a unique combination of properties. These new and unpredictable characteristics are illustrated by comparison with alkyl benzenes derived by alkylation of benzene with mixed butene polymers in the C12 to C16 range. In comparative o'i and discarded. The crude reaction mixture was next washed with` distilled water, dried by shaking with sodium bicarbonate and ltered to obtain 2700 grams (97%)y of product dissolved in excess benzene. Distillation of this mixture to obtain the monophenyl alkane gave the following yields:

tests alkylation of benzene with C12 olens from Volume. Weight. Boiling Range, 70 miXed butenes (boiling range 350 F. to 400 F. Fraction e Percent gms F at 760 mm A. P. I gravity 45.2) yielded only 29% of alkylate having a molecular weight corresponding to that t 57. 5 1, 557 175-455 zlflplieielnicdtoeanee 38.6 1,000 155-625 5 of the alkenes. Approximately 48% of the olen 30mm 3.9 143 (92% "ggg 5W no) Was lost to light alkylate by reason of degradav 75 tion or fragmentation, and about I23% was lost to' distillation bottoms. Conversion of olefin` to alkylate was about 86.3%. In contrastl thereto, alkylation of benzene With a C12 polypropylene (boiling range, 340 F. to 420 F., A. P. I. gravity, 41.6) gave an 80.5% yield of the corresponding monophenyl dodecanes with approximately 100% conversion. Subsequent sulfonation of the foregoing alkyl benzene from mixed butenes revealed 25.6% of unsulfonatable residue requiring purication for removal, and only 74.4% of the alkyl benzene was convertible to the sulfonate. On thel other hand, 97.2% of the monophenyl dodecane fraction from polypropylene was converted to the desired sulfonate and required no purification. Signicant distinctions in the structure of the mixed butene alkylate and the monophenyl dodecanes from polypropylene are shown by the fact that in a detergency test at 0.2% concentration (60% sodium sulfate lwas-40% sodium sulfonate) under comparable conditions, the polybutene benzene sulfonate gave a value of 1 as compared with a value of 46 for the sulfonated monophenyl dodccane fraction from polypropylene.

Continuing now with the flow sheet and conversion of the monophenyl alkanes, first, to a phenyl sulfonic acid-substituted alkane, and then to the sodium salt thereof, reference to Fig. 4 will reveal that the complex mixture of monophenyl alkanes from fractionator 33 flows through line 3d to the sulfonate process stage.

Ordinarily, the phenyl alkanes of this invention may be sulfonated directly Without further treatment, but provision is made in Fig. 4 for color stabilization and correction of off-color products by a preliminary extraction with a selective solvent for color bodies and their precursors. As here shown, the phenyl alkane may be sent to treater 36 through valve-controlled line |80 and contacted with a selective solvent for color bodies, preferably sulfuric acid. This preliminary treatment desirably is of `controlled severity (well understood in the art) sufficient to reach and selectively extract color bodies and unstable compounds, likely to form color bodies, but insucient to sulfonate the phenyl alkanes in significant amounts. Suitable acid concentrations and treating temperatures are from 95 to 98% sulfuric acid at 60 to 80 F. The phenyl alkanes are thoroughly contacted with the acid treating agent'and the mixture allowed to separate into an upper alkane layer and a lower acid layer containing the selectively extracted color compounds. The extracted phenyl alkanes next pass by way of valve-controlled overflow line |8| to the sulfonation stage.

In the usual case, the phenyl alkanes of this invention lmay flow directly to the sulfonation stage through valve-controlled by-pass line |83. As here shown, the fresh alkane feed passes by way of inlet line |82 together with reaction mixture into sulfonator 31. The sulfonation reaction is extremely rapid and is well over 95% complete at the time of mixing the fresh alkane With the reaction mixture. However, longer contact times are utilized and intimate dispersion effected to obtain substantially 100% sulfonation and insure against the presence of unsulfonated residues which tend to cause undesirable color or odor. A Contact time of up to about two hours assures these results and is obtained in the embodiment of Fig. 4 by the circulation of the reaction mixture from the bottom of the sulfonator through outlet conduit |85 to pump |86. Fresh acid Ais introduced by Way of inlet'line- |841.

indicated. Fresh phenyl alkane then iiows into the reaction mixture -at the 'outlet of the cooler and continues in the circulation cycle through feed inlet |82 to sulfonator 31.

Reaction temperature in the sulfonation 'zone' is important I and should be maintained sufciently high to effect complete sulfonatiom but not so high as to cause color deterioration crundesirable side reactions.- Exemplary operating conditions are illustratedV by sulfonation with 20 firming sulfuric acid in an amount of about 200 pounds ofacid for each 175 pounds of phenyl' alkane while maintaining the reaction temperature below a maximum of about 130` F; and generally above about F. with a residence time in the sulfonator under these conditions of! about two hours.

The sulfonated phenyl alkane togetherI with entrained acid is passed from'sulfonator 31 by'AWay of outlet line 38 either directly to the neutralization stage as indicated by valve-controlled bypass |38 or to settler 39 'by valve-controlled circuit |89. Water may be introduced into the re` action mixture through line |9| when' desired and facilitates separation of the acid and the sulfog nated oilylayer into separate phasesins'ettler' 39. Upon separation of the reaction mixture into separate phases, the lower sulfuric acid layer may be removed through outlet conduit |92 and recycled through valve-controlled line |90 to pump |86 when desired. In a typical operation, such as previously described, 15 to 35 pounds of acidswill be withdrawnA as a lower layer in settler 39 for each 200 pounds of acid originally introduced in sulfonator 31. The remaining sulfonated layer, when neutralized, will yield-a composition containing about 60% of the salt of sulfonated phenyl alkanes and about 40% sodium sulfate; The separation of acid layer is found further to irnprove color and odor ofinferior products. However, because of the high quality ofthe phenyl alkanes produces in accordance with this invention, such a separation is usually unnecessaryv unless the sulfate content of the sulfonate is to be reduced, and it is generally preferred to pass the sulfonated phenyl alkane together with its entrained acid directly to neutralizer 4| l Y In those instances Where settler 39 is utiliedt further improve color or to yield product of lower sulfate content, the sulfonated phenyl alkane flows by way of valve-controlled outlet |93 to neutralizer 4| Sulfonator 31 under the reaction conditions herein described yields a mixture of sulfonic acids in which the sulfonic acid group is directly attached to the benzene ring and this ring is in turn' attached to an alkane of polypropylene structure corresponding in molecular Weight to polypropylenes boiling within the ranges herein previously described. These'sulfonic acids, even after preliminary removal of entrained acid by gravity separation, contain 'some `free sulfuric acid. Thus, the; sulffcnationmixture iflowing'to neutre;-

23 lizer 4| by way of inlet line |94 is a mixture of sulfuric acid and sulfonic acids.

In the neutralization it is preferred to introduce the sulfonic acid mixture slowly into a vigorously stirred body of aqueous caustic soda solution previously fed to the neutralizer through line ISB in order that a more fluid solution will form. Also, an excess of alkali desirably should be present throughout the neutralization and until an end point of from about pl-l 7.0 to pH 8.5 is reached. This procedure gives a superior product and prevents local overheating and color deterioration occasioned by the reverse procedure of addition of caustic to the sulfonic acid reaction mixture. If desired, alcohol also may be added to neutralizer 4| further to increase fluidity of the reaction mixture and thereby promote effective contact between the reacting ingredients as well as better temperature control.

Temperature of reaction in the neutralizer is exceedingly important since it has been found that excessively high temperatures of neutralization instigate color deterioration. This is particularly true if the free sulfonic acids rather than sodium salts thereof are subjected to high temperatures, and it is for this reason that an excess of caustic is maintained up to the end point of the reaction while simultaneously maintaining temperature during neutralization below a maximum of about 130 F. and preferably no higher than about 120 F. In order to effect this temperature control, the reaction mixture is continously circulated by way of outlet conduit |91, pump |98 and cooler |99 back to neutralizer 9|. Heat of neutralization is removed in cooler |99 by circulation of any suitable heat exchange fluid therethrough as indicated in the drawing.

Builders or other additives for improving detergency or wetting action may be incorporated in the sulfonate salts of this invention as by introduction into the neutralizer through line 20|. Exemplary builders are trisodium phosphate, tetrasodium pyrophosphate, sodium silicate, and the like. Soluble magnesium salts in small amounts (for example 15%) also may be added. Alkali metal salts of high molecular weight carboxylic acids, such as the sodium salt of carboxymethyl cellulose, have been found to enhance detergency, particularly on cotton fabrics.

The sulfonate compositions of this invention maybe produced in the form of a concentrated aqueous slurry which may be sold as such but which is particularly adapted to yield a strong, hollow, globular, spray-dried product. The production of such a concentrated slurry, sufficiently uid to be pumpable at suitable handling temperatures, for example, T-130 F'. and yet which does not stratify unduly during handling or yield inferior spray-dried globules which collapse easily to form fines, requires a critical correlation of proportions yof ingredients. A suitable slurry should have a water content of at least 50% but no more than about 65%, and preferably from 55-60% by weight based on the total slurry. The solids content of such a slurry should contain no more than from about 30 to 50% by weight of the sulfonate, the remainder being inorganic salt exemplified by sodium sulfate with or without small amounts of tetrasodium pyrophosphate or similar builders.

In an exemplary production of a desirable slurry, the specific sulfonation reaction mixture described in connection with the sulfonation stageV is utilized, and -35 pounds of sulfuric acid is withdrawn. The remaining sulfonate layer is then neutralized with about 300 pounds of 41% caustic soda water solution and finished to a pH of about '7 .5. The resulting mixture will contain from about 55-65% water, and the solids will consist of about 60% neutralized sulfonic acid and about 40% sodium sulfate. It usually will be found desirable to build up the sodium sulfate content of this slurry to from 50 to 70% by weight of the sodium sulfonate content thereof to avoid gelling. This may be done by introducing additional sodium sulfate through valve-controlled line 202, and the sulfate so introduced may be obtained by means of neutralization of sulfuric acid from settler 39 with alkali such as sodium carbonate or sodium hydroxide as shown at 205. The finished slurry is readily handled as a pumpable mixture and may be spray-dried to form hollow globular particles of 20 to 40 mesh which are suiliciently strong to resist collapse or objectionable formation of fines during packaging and distribution.

In those instances where it may be desired for special reasons to produce a relatively pure sulionate, the aqueous slurry withdrawn from neutralizer 4| may flow from outlet conduit |91 by way of valve-controlled line 203 to an alcohol extractor 204 where addition of alcohol to the aqueous mixture serves to precipitate out the sodium sulfate or other inorganic salts and extract the sulfonate to yield a solution of the sulfonate in aqueous alcohol. This solution may then be passed by way of conduit 206 to a suitable recovery unit such as a drier 42. It is preferred, however, in most instances to utilize the sulfonate-sulfate mixture as previously described.

Depending uponthe nal use of the product and the most desirable physical form therefor, the aqueous slurry may be stored as such or converted to a dried product in any suitable drier 42. It has been found that a flake product, such as is formed on a drum drier, and a spray-dried product are preferred physical forms. An exemplary spray-dried product may be prepared in accordance with Lamont, U. S. Patent No. '1,652,900 issued December 13, 1927, to yield a preferred hollow, globular type substantially nondusting form found especially desirable for small 1ralccllrage marketing in the household detergent The sulfonate detergents herein disclosed possess surface-active properties to an exceptional degree and give marked effects in water at extremely low concentrations. As little as one molecule in 40,000 imparts marked foaming properties and good detergency even on grimy fabrics. One molecule of the detergent of this invention in a hundred thousand molecules of water is capable of decreasing the surface tension from '73 dynes per centimeter to 29 dynes per centimeter. Typical tests on such a nished detergent and wetting agent are: Alcohol soluble 40% Non-saponiable extract 0.4% Solution color 1% in water) 15 Saybolt pI-I (1% in water) 7.0-8.0

Bulk density (dried form) 0.2 to 0.4 gm./mol

Unless otherwise indicated, the following test data are on a detergent product containing about 60% sodium sulfate and having the foregoing properties.

To illustrate more specically the detergency properties of the compounds and compositions herein disclosed, tests were run on heavily soiled minute Washes and tWo ten-minute rinses were given. The results expressed as per cent'soil removall are given below:

` 'Concentration Soil Removal Percent Percent Similar tests on cotton have shown that the detergent of this invention is excellent for `this fabric also and that it responds well to various types of builders. For example, in a test such as that above, but Yusing a heavily-soiled finelywoven (and hence dicult to clean) cotton at a temperature of 140 F., ra high grade commercial soap at 0.2% concentration has a detergency rating of 100, Whereas the detergent herein disclosed at the same concentration has a detergency rating o'f 265. It is indicated also that in tests in hard vwater on cotton cloth soiled according to the method given in U. S. Navy Specification 51-S47 (Int) Bureau of Ships, October 1,1945, this detergent has extraordinary synergistic action in conjunction with alkaline builders, such as trisodium phosphate.

Apparatus and procedure as described'by Ross and Miles (Oil and Soap, May 1941, pages'99-102) were used to check the height to which foam rose in a jacketed tube when 200 cc. fell in a ne stream down through a distance of 90 centimeters. The test was run in 300 p. p. m. hard Water and p; p. m. hard Water with solutions and apparatus maintained at 110 F.

Weight Percent Concentration Height In 300 p. p. 1n. Water:

Similar tests run by the method of Ross `and Miles at 110 F. with total solids held at ra fooncentration of 0.2% while various Yratios of lthe detergent of this invention and alkalies, such as trisodium phosphate, were employed` gaveioam heights as stated.

Foam height by Ross-Miles Test sulfonate detergent and trisodium phosphate p. p. m. hardness water' Y [Total solids=0.2%]

Sulfonate 'Trisodium Foam Detergent Phosphate Height Percent Percent Mm.

100 0 185 80 20 215 40 222 V50 50 225 40 6o 212. 2o so4 I .200 10 90 -183- V0 ',100 0 noo r26 One inchsquares of 10 oz. vcotton duck were observed .for the time in seconds required for them towet and sink in the detergent solutions of varying concentrations in Ydistilled Water, 1% sodium 'hydroxide and 5% sulfuric acid.

` Wetting time `[l0 oz. CottonDuck] Concentration, percent Dgd mi@ gxiillg Graphical interpolations .in the -above datagive the concentrations of the detergent of lthis invention necessary for.v 2 5 Vsecond wetting .time *as 0.28% in `distilled Water, -0.27% -in 1% vsodium hydroxidaiand `0.31% in 5% sulfuricfacid.

`Cotton-wetting tests run by the Draves'method for wettingand sinking astandard skein of yarn Were run at 25 C. in distilled Water, 1% rsulfuric acid and 1% sodium hydroxide- .A three-'gram hook Wasused.

Draves Sinking Time'v ConeentrationDetergent, v

Percent Distilled 1% sul 1% sodium ater. furie Acid Hydroxide Overl 24 '250' 300`i 167 25 40;-A 5 29. 9 5. 9 6. 5 r8. 3 3. 2 2.*91 15. 7 2. 8 2. 5 v4:5 2. 4 2. 2

MinimumTemp. (E.) for .Clear .Solution Concentration Detergent,

Percent 1% Sodium Hydroxide Distilled 1%,Su1furic Water Acid .At il68 F. the. clearisolubility Aoi.v detergent in 'either distilled-Water or-1% sulfuric vacid isy indi- A cated as Aapproximately 2.3%.

.concentrated/.hard Water -to a `:point where the turbidity just l, obscured the :markings fonl a A50 ecc. graduated cylinder as observed through ,the

15 solution...

' is given by the following test.

room temperature, it can be solubilized by use of a lower molecular weight sulfonate to give solu-` 'tions running as high as 24% of detergent and 31% ofl total solids at room temperature. A

- suitable solubilizing sulfonate is any of the highly water soluble Vtypes such as those recovered in the acid treatment of light petroleum fractions v or an isopropyl to hexyl benzene sulfonate. Dilution of these concentrates gives solutions usable -at slightly lower temperatures.

At room temperature (25 C.) 10% isopropyl alcohol will dissolve the sulfonate detergent to give 20% by weight in the solution. Isopropyl alcohol in strengths from 7% up to 20% readily dissolves of the sulfonate detergent at room I temperature. However, at 40 C., 7.5% to 12.5%

isopropyl alcohol can dissolve of the sulfonate of this invention.

Surface tension measurements at C. run on Du Nuoy Tensiometer are given as well as interfacial tensions relative to a U. S. P. White Oil of 29.5 dynes per centimeter surface tension. Results are given for solutions in 300 P. P. M.

` hard water as well as distilled water.

Aninustretion ef the stability of this detergent Y Two per cent of the sulfonate detergent dispersed in 10% sodium hydroxide was reiiuxed for 24 hours at a temperature of approximately 215 F. An air jet on theV surface was used to keep down foaming.

' Samples taken from the beginning and end of thevrun were diluted with nine parts of water and tested for foam height and wetting time.

` cotton duck.

. Inl. asks.

l Meinmisswater 'rest Used I initial Final 8l' Il 0l' y Concentration Detergent Percent Foam (Ross-Miles) mm" 228 230 Calcium Car- 5 Wetting Time (10 oz. duck) sec.. 19 24 bonate A similar test was run on a solution of 1% of 0j coo detergent in 15% sulfuric acid, which was then .3.19 2% 10 reuxed for 24 hours. ;Samples from the Abe- Ojogj "j: 384 ginning and end of the test were diluted nine to A Y one with water and checked for wetting time.

More concentrated solutions of the sulfonate detergent are capable of giving clear solutions in Tesmsed Initial Final even harder water. Y 15 p Though the sulfonate detergent by itself is ,gm Sea "s01uble 't0 the extent, of approximately 2% at wetting Time (10 OZ- duck) 29-1 35-1 The surface active properties of this detergent are not destroyed by boiling with 10% caustic or 15% sulfuric acid.

A solution of 0.2% of the detergent of this invention in 0.25% sodium hypochlorite was A check on the wetting times of the solution at start and finish gave 18.2 sec. initially and 17.3 sec. finally on 10 oz.

Further than this a 0.2% suspension ofthe detergent in 5.2% sodium hypochlorite solution was analyzed at the beginning and end of a four day observation. The available chlorine determined iodimetricallywas unchanged at the end of the test.

It appears there is negligible effect of dilute Vhypochlorite on the detergent or of detergent upon the hypochlorite.

Thetoleration. of `this. detergent for various metal salts is expressed below. Ten ml. volumes of a 1% solution of detergent were placed in 25 One percent .solutions of the metallic salts were added to separate samples near the boil point in Vdropwise fashion from a burette until it was no longer possible to see through the solution. The results are expressed as number of milligrams of metallic salt added to cause turg bidity.

Aluminum Sulfate Mgs. to Cause Tur- Barium Chloride Calcium Chlorid Copper Sulfate Ferrie Sulfate Lead Nitrate Magnesium Sulfate Mercurio Chloride. Nickel Nitrate Zinc Nitrate The sulfonate compositions Vherein disclosed have a variety of applications in industry exempliied by the following:

Quicker break and easier rinsing on all goods merit applications in commercial laundries for the washing of woolens and line fabrics as well as for grease and soil removal from high oil content washes such as overalls and oil wiping cloths.

In the metal cleaning industry the sulfonates of this invention may be utilized for degreasing, corrosion inhibiting or the like in acid pickling and clean rinsing solution.

High sanitation in household dishwashing and of equipment and buildings in dairy cleaning and @assignee `flood processing is obtainable withxthese v'deterigents which 'are particularly fadapted for washing of fruits and vegetables 'prior to packing or quick freezing.

Use v-in liquid. paint cleaners for better grime removal without effect fon paint luster, and utilization for automobile washingto give .sparkling finish on weathered surfaces, 'further illustrate lthe attributes -ofithe present fsulfona'ted phenyl- 'substituted alkanes Likewise, these compounds may be utilized for wool scouring, for penetration andevennessin dyeingandiillingtextiles, in pig.-

ment processing-to make water colors and fillers for paper, cement, and water paints-as well as to improve wetting and spreading of insecticides or herbicides and to increase penetration thereof. These -sul'fonates .-also 'find application A``rin blends v .with ysodium bisulfate or With alkaline builders in industrial cleaning compounds. Again the ysurface-'activity of the sulionated compounds of this invention adapts them for use incre processing as a collector and frothin'g agent andin pulp and paper processing 'for debration, bleaching and rinsing.

To further illustrate the foregoing and other uses of the products herein disclosed, the following examples are given. In these examples, the mixed sulfonated phenyl-substituted polypropylene alkanes are utilized in the form of the sodium salts and contain about-40% by weight of sodium sulfate unless otherwise indicated. For convenvien'ce this rmixed product is `hereinafter Videntied as sul'fo'nate 'detergent for Fas polypropylene-benzene sulfonate detergent. It "will be 'understood that these examples fare merely illustrative.

EXAMPLE 13 Cleansing composition About three parts by weight of sulfonate detergent is dissolved in 500 parts of Water. The solution is a cleanser for painted surfaces.

EXAMPLE 14 Laundering composition To 70 gallons of water add one pound of polypropylene benzene suli'onate, one pound of sodium chloride and Yone-'fourth pound or" soda ash. This solution when employed in a washing machine forms va `cleansing agent Acharacterized by its marked ability to vremove dirt kand Vstains Aas Well as its ability to function either r'in hard =or sof-t Water.

EXAMPLE 15'l Cleansing composition for Vfibrous material Sulfonated phenyl polypropylene alkanes containing 2% by Weight of lauryl alcohol when dissolved in water to Vform a .6% aqueous solution suitable for cleansing brous material such as wool, cotton or the like.

.EXAMPLE 116 Securing composition forsodium carbonate. Water soluble alcoholsilikewisemai7 beadde'd.

30 .EXAMPLE .i7

Cleansing composition for 'raw wjo'ol An aqueous solution containing 0.5% soda -ash and 0.2% sulfonated phenyl polypropylene alkane is-prepared. Raw Wool whichhas fbeenapreviously treated 15 minutes in an aqueous 08% soda ash solution -at F. is next treatedfin the sulfonate bath for 15 minutes at about 115 F. and subsequently rinsed. The Wool is well cleaned and substantiallyiree from' natural waxes and fats.

vlilxl-Mie'mi;118

Cleansing composition Ten parts of normal cetyl sodium sulfatatwenty parts of diisopropylene naphthalene sodium sulfonate and seventy parts of sulfonatedphenyl polypropylene alkane are mixed. lTwo Vparts of this mixturemay*beidissolved in 500-parts'oiwater to .produce -a ,a cleansing solution for cottomssilk, Woolorrayon.

Emiraten-19 .Polish Five par-ts voi carnauba Wax are imelted'by heating to about 90,C5andfthe melted Waxadded With vigorous stirring to an aqueous solution containing a small amou't of sulfonate detergent (for example, 5.%"). ALsmooth-"emulsion is produced which has marked polishing andl cleansing action when applied in the usual manner to furniture, leather, automobiles `and .other.highly polished enamehlacquered or paintedsurfaces.

"EXMPLE :'20

Soap composition One to two parts of sulfonate detergent may be added to one part of ordinary soap to inhibit precipitation from hard water 'and prevent -the formation of curds or tacky deposits.

llmiMrnE 21 Cleansing composition Ninety-five parts of rsulfonate'd phenyl polypropylene alkane from which inorganic salts have been removed by treatment with lalcohol :EXAMPLE .22-

yCleansing composition An excellent detergent .may be obtained by mixing from 20 to 8-0 parts by weightof sulfonate detergent with 80-20parts by weight-of an `alkyl sulfonate detergent vsuch as is obtained by the chlorosulfonation of long-chained aliphatic vhydrocarbons ormixtures thereof such asa parafnic petroleum fraction having-an average molecular weight of 175 to 500. `A suitable ymaterialmay be prepared by the process of Reed, Reissue Patent No. 20,968, issued January .3, ,1939.

Emulsion n.aqueous solution `prepznfed .containing EXAMPLE 24 Wetting composition Five parts of paratertiary amyl phenol and ninety-ve parts of sulfonate detergent are mixed. One part of this mixture in one hundred parts of water greatly enhances the wetting action thereof.

EXAMPLE 25 Cleansing and bleaching of cotton cloth 0.4 to 1% of sulfonate detergent is added to a sodium hypochlorite solution containing 0.7% available chlorine. Heavily woven unbleached cotton cloth or unbleached cotton yarn may be immersed in this solution at room temperature for about 5 minutes, squeezed, exposed to the air until bleached and then rinsed and treated with antichlor in known manner.

EXAMPLE 26 Y Sizing composition Three hundred parts of magnesium sulfate and two parts of sulfonated phenyl polypropylene alkane are dissolved in one thousand parts of water. The resulting solution is utilized in the sizing of brous materials such as cotton in the well-known manner.

EXAMPLE 27 Pigment dispersion One-half part of lampblack is added to a solution of one part of sulfonate detergent in five hundred parts of water. The lampblack is rapidly dispersed throughout the solution with agitation.

The sulfonated phenyl alkane detergents of this invention may be used in combination or admixture with other wetting agents and detergents of either the anionic or non-ionic type. In general, from about four parts of sulfonated phenyl polypropylene detergent to one part of the additive wetting agent or detergent on the one hand, to from about one part of said sulfonated phenyl polypropylene detergent to four parts of the additive, may be utilized. Further, such admixtures may contain inorganic salts, such as sodium sulfate, trisodium phosphate, sodium silicate, tetrasodium pyrophosphate, and the like. In the case of anionic additives the mixture usually will contain sodium sulfate or the like in an amount of from about Ll0--80% by weight based on the entire detergent composition. Additive wetting agents and detergents of the above-mentioned anionic type, which may be utilized in combination with sulfonated phenyl polypropylene detergents as disclosed, are exemplified by primary alkyl sulfates, secondary alkyl sulfates, sulfated glycerol esters, aliphatic sulfonates, sulfonated esters or amides of fatty acids (Igepons), sulfonated or sulfated polyglycol ethers of alkyl phenols, mixtures of sulfonate-substituted compounds obtained by addition of nitrosyl chloride to an olen followed by reaction with sodium sulte, alkyl sulfoacetates, salts of alkenyl succinic acids and salts of monoalkyl esters of alkenyl succinic acids. Non-ionic types of wetting agents and detergents likewise utilizable in combination withA sulfonated phenyl polypropylene detergents as previously disclosed are illustrated by polyglycol ethers of alkyl phenols, polyglycol esters of fatty acids, alkyl polyglycol ethers, polyglyco-l derivatives of alkyl amines, condensation products of 1,3 dioxolane (glycol formal) and fatty acids, glycerol and glycol esters of fatty acids, alkyl polyalkylene polyamines. In general it should be noted that anionic wetting agents and detergents are characterized by a polar group, such as:

Non-ionic detergents are characterized by ether, ester, amino and analogous polar groups.

The following detailed disclosure illustrates various preferred types of additive wetting agents and detergents which may be utilized in combination with sulfonated phenyl polypropylene detergents of this invention in proportions of from about to about 20% of polypropylene type detergent to from about 20 to about 80% of the additive.

I. Aliphatic snlfates (l) Primary and Ysecondary alkyl sulfates Examples: Lauryl sodium sulfate, cetyl sodium sulfate, polypropylene sodium sulfate, Keryl sodium sulfate.

(2) Sulfated esters (a) Sulfated diglycerides Examples: Sulfated monoand diglycerides from cocoanut oil, palm oil, lard oil, and the like.

and diglycerides from cocoatlie like.

Examples: Sulfated mononut oil, palm oil, lard oil, and

(3) Sulfated ethers (a) Sulfated glyceryl di-ethers (b) Sulfated glyceryl Vmono-ethers Examples: Octyl, lauryl, cetyl, monoand di-ethers of glycerine.

II. Sulfonates (1) Alkyl sulfonates Examples: R may be octyl, decyl, cetyl, paraiiin wax, pitliyprfpylene, kei-y1 or other mineral oil aliphatic type r 1 a s. 

6. A SOLID PARTICLE FORM SYNTHETIC DETERGENT CHARACTERIZED BY HIGH RESISTANCE TO CAKING AT HIGH RELATIVE HUMIDITY AND HIGH ATMOSPHERIC TEMPERATURE PREPARED BY FORMING AN AQUEOUS SLURRY CONTAINING AS ITS SOLID COMPONENTS 20 TO 40% BY WEIGHT OF ACTIVE DETERGENT MATERIAL AND 60 TO 80% BY WEIGHT OF INORGANIC BUILDERS, THE ACTIVE DETERGENT MATERIAL CONSISTING ESSENTIALLY OF 10 TO 30% BY WEIGHT OF AN ALKYL SULFATE CONTAINING 8 TO 12 CARBON ATOMS IN THE ALKYL GROUP AND 70 TO 90% OF A MONOALKYL BENZENE SULFONTAE HAVING A POLYPROPYLENE RADICAL CONTAINING 12 TO 15 CARBON ATOMS AS ITS ALKYL GROUP, AND SPRAY-DRYING THE SLURRY. 